electronic mixing machine pu 3000 - grapek actionhp fluid regulator, model 3/8 (260 bar / 3771 psi)...

INSTRUCTION MANUAL

ELECTRONIC MIXING MACHINE PU 3000

Manual : 1209 573.199.112

Date : 03/09/12 - Cancels : 21/02/12

Modif. : Pages 35, 37 & 42 (greases)

TRANSLATION OF THE ORIGINAL MANUAL

IMPORTANT : Before assembly and start-up, please read and clearly understand all thedocuments relating to this equipment (professional use only).

THE PICTURES AND DRAWINGS ARE NON CONTRACTUAL. WE RESERVE THE RIGHT TO MAKE CHANGES WITHOUT PRIORNOTICE.

KREMLIN REXSON

150, avenue de Stalingrad93 245 - STAINS CEDEX – France

Téléphone : 33 (0)1 49 40 25 25 Fax : 33 (0)1 48 26 07 16

www.kremlin-rexson.com

KREMLIN REXSON Page 1 Manual : 573.199.112

TABLE OF CONTENTS

1. SAFETY INSTRUCTIONS ........................................................................................................................... 4

GENERAL SAFETY INSTRUCTIONS.........................................................................................4 SPECIFIC SAFETY INSTRUCTIONS .........................................................................................4 ENVIRONMENT...........................................................................................................................5

2. DESCRIPTION............................................................................................................................................. 6

3. OPERATING DESCRIPTION....................................................................................................................... 8

4. FEATURES .................................................................................................................................................. 8

5. INSTALLATION ........................................................................................................................................... 9

HANDLING...................................................................................................................................9 STORAGE....................................................................................................................................9 ENVIRONMENT ON THE AREA.................................................................................................9 DESCRIPTION OF THE LABEL MARKINGS............................................................................10 INSTALLATION DIAGRAM........................................................................................................11 INSTALLATION .........................................................................................................................12 CONNECTION OF THE CONTROL BOX AND OF THE FLUID FRAME .................................13

6. OPERATING .............................................................................................................................................. 13

DRIVING FROM THE MACHINE...............................................................................................13 SWITCHING ON THE MACHINE..............................................................................................14

7. FIRST SWITCHING ON ............................................................................................................................. 14

8. FIRST PLACING INTO OPERATION........................................................................................................ 15

BEFORE SWITCHING ON ........................................................................................................15 FLUSHING OF THE PUMPS AND OF THE MACHINE IN SOLVENT......................................16 START UP OF THE MACHINE .................................................................................................16 MIXING RATIO CHECKING ......................................................................................................17

9. APPLICATION PROGRAMMING (F3) ...................................................................................................... 17

PASSWORD..............................................................................................................................18 PARAMETERS ..........................................................................................................................19 VALIDATION OF THE INITIALIZATION MODE........................................................................20 PRODUCTION (F1) ...................................................................................................................21 FLUSHING (F2) .........................................................................................................................22 CONSUMPTIONS / PRINT (F4) ................................................................................................22

10. INDICATIONS OF OPERATION GIVEN BY THE MACHINE.................................................................... 24

INDICATIONS GIVEN BY THE LEDS .......................................................................................24 MESSAGES GIVEN BY THE DISPLAY UNIT ...........................................................................24


11. MAINTENANCE ......................................................................................................................................... 25

SYNOPTIC.................................................................................................................................25 MAINTENANCE PLAN...............................................................................................................26 TROUBLESHOOTING...............................................................................................................27 DIAGNOSTICS ..........................................................................................................................27

12. PROPORTION AND OUTPUT ACCORDING TO THE RATIO ................................................................. 28

13. MIXING RATIO........................................................................................................................................... 29

14. PNEUMATIC AND ELECTRIC DIAGRAMS.............................................................................................. 29

15. FEATURES - PU 3000 PNEUMATIC......................................................................................................... 31

COMPOSITION .........................................................................................................................31 TECHNICAL FEATURES ..........................................................................................................31 SPECIFIC PARAMETERS.........................................................................................................31

16. FEATURES - PU 3000 AIRMIX............................................................................................................... 32


17. DISASSEMBLY & REASSEMBLY - PU 3000 PNEUMATIC, PU 3000 AIRMIX .................................... 33

MIXER........................................................................................................................................33 PILOTED VALVES.....................................................................................................................33 FLUID SECTION, MODEL 50 (BASE) (REFER TO DOC. 573.080.050) ..................................34 FLUID SECTION, MODEL 50 F (CATALYST) (REFER TO DOC. 573.114.050)......................36

18. FEATURES - PU 3000 AIRLESS............................................................................................................... 39


19. DISASSEMBLY & REASSEMBLY - PU 3000 AIRLESS .......................................................................... 40

MIXER........................................................................................................................................40 ASI 40 VALVES (REFER TO DOC. 573.062.050).....................................................................40 FLUID SECTION, MODEL ALTO 50CC (BASE) (REFER TO DOC. 573.395.050) ..................41


ADDITIONAL DOCUMENTATIONS :

Incorporation declaration and EC declaration ofconformity

578.013.130-UK

PU 3000 PNEUMATIC

Spare Parts

PU 3000 Pneumatic Pump - Assembly Doc. 573.404.050

Pneumatic motor, model 1500 (only for PU3000) Doc. 578.009.110

BASE fluid section, model 50 Doc. 573.080.050

CATA fluid section, model 50F Doc. 573.114.050

Color changer and valve Doc. 573.187.050 + Doc. 573.188.050

LP fluid regulator (Spring operated) Doc. 573.203.110 + Doc. 573.415.050

HP fluid regulator, model 3/8 (260 bar / 3771 psi) Doc.573.299.050

PU 3000 AIRMIX

Spare Parts

PU 3000 Airmix Pump - Assembly Doc. 573.386.050

Pneumatic motor, model 3000 Doc. 573.387.050

BASE fluid section, model 50 Doc. 573.080.050

CATA fluid section, model 50F Doc. 573.114.050

Color changer and valve Doc. 573.187.050 + Doc. 573.188.050

Filter, model HP 3/8 (260 bar / 3770.8 psi) Doc.573.299.050

PU 3000 AIRLESS

Spare Parts

PU 3000 Airless Pump - Assembly Doc. 573.389.050

Pneumatic motor, model 5000 Doc. 573.390.050

BASE & CATA fluid section, model 50cc Doc. 573.395.050

ASI40 valve Doc. 573.062.050

Filter, model HP 3/4 (360 bar / 5222 psi) Doc. 573.327.050

DIAGRAMS

Pneumatic and electric diagrams 055.680.031


Dear Customer, You are the owner of our new PU 3000 mixing system and we would like to take thisopportunity to thank you.

Special care has been taken during all designing and manufacturing process to make sure yourinvestment will provide full satisfaction. Non-compliance with instructions and precautions stated inthis manual could reduce the equipment working life, resulting in operating problems and createunsafe conditions.

1. SAFETY INSTRUCTIONS

GENERAL SAFETY INSTRUCTIONS

CAUTION : The equipment can be dangerous if you do not follow ourinstructions concerning installation and servicing described in thismanual and in accordance with applicable European standards and localnational safety regulations.

Please carefully read all the instruction literature before operating yourequipment.

Only trained operators can use the equipment (To acquire an essential training, please contact the"KREMLIN REXSON University" training center - Stains).

The foreman must ensure that the operator has understood the safety instructions for this equipment aswell as the instructions in the manuals for the different parts and accessories.

Read carefully all instruction manuals, label markings before operating the equipment.

Incorrect use may result in injury. This equipment is for professional use only. It must be used only forwhat it has been designed for. Never modify the equipment. The parts and accessories supplied must beregularly inspected. Defective or worn parts must be replaced.

Never exceed the equipment components' maximum working pressure.

Comply with regulations concerning safety, fire risks, electrical regulations in force in the country of finaldestination of the material. Use only products or solvent compatible with the parts in contact with thematerial (refer to data sheet of the material manufacturer).

Refer to 'Installation and safety instructions' document(doc. 578.001.130)

SPECIFIC SAFETY INSTRUCTIONS

The control box of the PU 3000 mixing machine shall be installed outside theexplosive area. It shall be installed in a safe area (non-explosive areaaccording to the ATEX directive - refer § 7).

P

Do not install the paint drums underneath the pumps or the electric equipments. Placethem in front of the frame. Install a cover on the drums to reduce the diffusion of gasand vapours in the booth.

Connect the control box to the mains supply fitted with a ground.

The fluid module is fitted with a ground. Connect the ground cable to earth.

L

Do not use any product or solvent incompatible with the machine components.

Use the appropriate solvent for the material being sprayed to increase the equipmentworking life.

Wear protective glasses to protect the operator from possible discharges during thehandling of the machine.


P

CAUTION : To prevent from any formation of gas and inflammable vapours,use paint whose flash point is the highest possible (refer to materials' safetyinstructions).

Before cleaning or removing components of the equipment, it is compulsory :

1 - to shut off the air supply,

2 - to open the gun fluid circuit and depressurize the hoses,

3 - to switch off the machine electrical supply.

ENVIRONMENT

This equipment consists of a label plate with the name of the manufacturer, theequipment part number, the interesting informations to use correctly theequipment (pressure, voltage…) and the above pictogram.

The equipment is designed with and consists of high quality materials andcomponents which can be re-used.

The 2002/96/EC European Directive covers all equipments with a crossed-out binpictogram. Please inform yourself about the collection systems for electric andelectronic equipments.

Please act in accordance with local rules and do not dispose of old equipment with householdwastes. A correct disposal of old equipment will help prevent negative consequences for theenvironment and health.


B

2. DESCRIPTION

The PU 3000 proportioning system is designed for applying two component solvent or water-based paintsand lacquers.

There are three versions available :

- a pneumatic version (maximum pressure : 0-6 bar / 0-87 psi or 6-40 bar / 87-580 psi)

- an AIRMIX version (maximum pressure : 180 bar / 2610 psi),

- an AIRLESS version (maximum pressure : 350 bar / 5076 psi),

It is under an independant form only supplied with compressed air (maximum 6 bar / 87 psi) and anelectric supply (115V / 230V).

It consists of :

- a control box with PLC and electromagnetic control components,

- a frame supporting a BASE pump, a CATALYST pump, the automatic valves for the materials and thesolvent, and electropneumatic control components.

A : Electronic control box with display unit

B : Air equipment

C : Mixing unit

HB : BASE fluid section

HC : CATALYST fluid section

MP : Pneumatic motor

30 : Mixer

Option : Flushing pump

Nota : drawing of a pump, model PU 3000 Airmix

A

MP MP

C

HB 30 HC


FRONT VIEW OF THE CONTROL BOX

Ind. Description Fonction

13 Red LED Fault

14 Orange LED Working (other than production)

15 Green LED Production

The machine is totally programmable via a man/machine interface. The screen indicates continously, by asimple identification, the status of the machine and it enables the operator to have access to the essentialfunctionalities : ON / OFF - FLUSHING / PRODUCTION.

The information relating to the operating of the machine (real time display of the ratio, of theconsumption…) can be read on the LCD screen.

The PU 3000 continously saves data on the consumptions of base, catalyst and solvent as well as thetotal consumptions and the emissions of Volatile Organic Compounds (VOC) during the operation of themachine.

On the box of the machine, a seal gland enables an electrical supply to the machine with electricity via asafety isolating switch (115V / 230V).

The pictograms located under the screen allow the user to remember easily the various functionsmanaged by the PU 3000.

Pictogram Mode

Production

Flushing

Parameters

Consumptions / Print

Feeding of the pumps

14

15

13


3. OPERATING DESCRIPTION

The 2 BASE and CATALYST materials are sent to the mixing machine from 2 pumps.

In production, as well as in regeneration, the machine injects a small volume of catalyst (P-6) in the basecontinuous flow.

The PLC continuously checks the mixing ratio and if it notices a fault that it cannot correct, an alarm isactivated. The machine goes into safety mode.

The capacity of the pumps is configured (for the BASE pump : P4 parameter, for the CATA pump : P5parameter) depending upon the equipment versions.

4. FEATURES

Number of colors : 1

Number of catalyst : 1

Solvent and water-based paints compatibility

Control via a magnet in the control box

Continuous mixing check

Adjustable threshold alarm

Adjustable pot-life indicator

Automatic flushing cycle (time)

VOC display

Consumptions' total indicator : base, cata, solvent,VOC

Printing (connection to a printer)

Voltage : 230V / 115V - 10W

Air pressure: Mini 4 bar / 58 psi - Maxi 6 bar / 87 psiOperating pressure :from 0-6 bar / 0-87 psi or from 6-40 bar / 87-580 psifor the pneumatic versionfrom 30 to 180 bar / from 436 to 2610 psi for theAirmix versionfrom 60 to 350 bar / from 870 to 5076 psi for theAirless version

Adjustable mixing ratio : from 0.6/1 to 20/1 (BASEvolume / CATALYST volume) (from 160% to 5%)

Mixing precision : 1 %

Répeatability : 1 %

Mixed fluid output : refer to § 14 & 15

Maximum operating temperature : 50° C / 122° F

Weight : 115 kg / 253.5 lb (Pneumatic version)187 kg / 412 lb (Airmix version)217 kg /478 lb (Airless version)

Dimensions :

- Control box : 355 mm x 275 mm x 135 mm

- Fluid frame : 855 mm x 670 mm x 1270 mm(Airmix version)960 mm x 670 mm x 1400 mm (Airless version)

Connections :

Air inlet : F 3/4 BSP (air inlet valve)

Fluid outlet (mixer) :

F 3/4 JIC or assembly of a fitting ( M 1/2 JIC)


5. INSTALLATION

HANDLING

The PU 3000 system with relevant weight and dimensionsmust be handled by appropriate means.

Nota : The handling of the machine must be carried out by aqualified staff, in an appropriate space, correctly cleared toavoid any risks of fall or of crushing of people.

Nota : The ring located above the cover is for thehoisting of the pump and shall not be used for thehandling of the complete machine.

The frame has 4 holes ( 9) to be fixed on a bracket or onthe floor.

STORAGE

Storage before installation :

- Storage ambient temperature : 0 / + 50 °C. / 32 / +122° F

- Protect the equipment against dust, running water, dampness and shocks.

Storage after installation :

- Operating temperature : + 15 / + 35 °C. / + 52 / + 95° F

- Protect the equipment against dust, running water, dampness and shocks.

ENVIRONMENT ON THE AREA

The pump must be installed on a horizontal stable floor (eg : flagstone).

Ensure the machine is stable.

The working area must be correctly ventilated.


DESCRIPTION OF THE LABEL MARKINGS

The PU 3000 machine is fitted with 2 label markings : a plate on the control box and another one onthe fluid equipment.

Marking label on the control box

(box located outside the spray booth)

Marking label on the frame

(frame assembly located inside the spray boothmarking in accordance with the ATEX directive)

Marking according to the ATEX Directive

KREMLIN REXSONSTAINS FRANCE

Name and address of the manufacturer

CE II 2 GII : group II 2 : class 2

Surface equipment meant to area where explosive atmospheres due to gas,vapours, mists are liable to appear from time to time in usual operating

G : gas

P air : 6 bar / 87 psi Maximum air pressure

P prod : Maximum fluid pressure

Série / Serial Number given by KREMLIN REXSON. The two first numbers indicate themanufacturing year.

Ref Part number of the PU 3000 machine

Phase Single phase

Fréquence 50-60Hz / Mains frequency

Ampérage Maximum current used


INSTALLATION DIAGRAM

A Potentially explosive area : area 1 (Z1) or area2 (Z2) (spray booth)

6 PTFE HP fluid hose

B Non explosive area (safe area) 7 Automatic valves

1 PU 3000 control box 8 Mixer

2 BASE pump 9 Electrovalves

3 CATALYST pump 10 HP Fluid hose (not supplied)

4 Flushing pump (option) 11 Gun (not supplied)

5 HP fluid hose 12 Gun spraying air from the machine

The 1 m / 39.37" distance indicated in these diagrams is given for information only andholds harmless KREMLIN REXSON. The user is liable for the exact delimitation of theareas which depends on the material used, the material environment and on the useconditions (refer to EN 60079-10 standard). The 1 m / 39.37" distance could bemodified if analysis carried out by the user deems it necessary.

2

10

B

A

Z1

Z2HC

1m

B

1

34

7

5 5 6

8

9

11

12


P

The control box must be connected to a supply fitted with a ground.The bracket of the pumps is fitted with a ground cable. That must be grounded.

Do not install the paint drums underneath the pumps or the electric equipment.Place them in front of the frame. Install a cover on the drums to reduce the diffusionof gas and vapours in the booth.

The electrical cable connecting the chassis mounted electric components to thecontrol box must be installed so that at no time is any risk from mechanical damage,chemical corrosion or excessive heat. Please ensure that the wiring loom is keptseparate from any other electrical cables that are not intrinsically safe.

INSTALLATION

There are different ways to install the PU 3000 to answer to the majority of the installations.

The control box of the PU 3000 mixing machine must be installed outside thespray booth in a safe area.

Assembly for piloting outside the booth :

The machine is in two parts to enable the controlbox to be fitted outside the booth (cable of 8 m /26.2 ft between the 2 elements).

Nota : Drawing of a pump,model PU 3000 Airmix

Assembly for machine control in the booth :

There is a booth mounting control kit (availablein option).

That kit enables the user to fix the control boxon the booth by means of a glass panel and tocontrol the machine inside the spraybooth..

The control is carried out thanks to a magnetprovided with the machine. The distancebetween the control box and the fluid frame isof 8 m / 26.2 ft (cable supplied with themachine).


CONNECTION OF THE CONTROL BOX AND OF THE FLUID FRAME

Fuse 160 mAfor machine with serial number < to 09Y1080

Fuse 315 Mafor machine with serial number >to 09Y1080

The PU 3000 must be connected to adry and clean compressed air network(minimum 4 bar / 58 psi) and to a singlephase electric supply (115 V / 230V)connected to an isolating switch. Thenetwork ground will be connected in thecontrol box on a connect provided.

Before connecting the PU 3000,be certain the mains voltage is thesame as the one of the machine (230V).If no, open the electric box removing theprotective housing and move the jumper(230V 115V).

Install a fluid hose, model HP (highpressure) between the mixer outlet and

the spray gun ( act according to thepressures the pumps supply).

Connect the air equipment of the PU3000 to the pneumatic network with aconductive hose (minimum 16 mm / 5/8dia).

Nota : these hoses are not supplied inthe standard version.

The air connection of the machine isFemale 3/4 BSP (air inlet valve).

The connection between the control boxand the electrovalves located on theframe, is carried out via cable, length : 8m / 26.2".

6. OPERATING

DRIVING FROM THE MACHINE

SCREEN

Different menus and information relating to the machine are displayed on the alphanumeric screen.

KEYBOARD

ESC That key enables the user to quit the menus or the different modes (production,flushing, parameters).

OK That key enables the user to enter in the different menus or to validate a value ofparameter.

▲ That key enables the user to shift from a menu to another and to increase the valueof a parameter during modifications of value.

▼ That key enables the user to shift from a menu to another and to decrease the valueof a parameter during modifications of value.


The keyboard is controlled thanks to a magnet provided with the machine. That control mode enables theuser to drive the machine inside the booth if the box is installed behind the booth glass panel. Thistechnology enables the operator to save time and to carry out his work from the place application.

SWITCHING ON THE MACHINE

The placing of the system into operation requires that the BASE, CATALYST andSOLVENT drums are full enough to ensure the production.

Connect the gun before placing the system into operation.

Unscrew the 3 air regulators before supplying air to the installation.

Supply air to the PU 3000 (minimum 4 bar / 58 psi).

Switch on the control box (switch located on the side of the box).

When switching on the control box, a menu is displayed on the screen.

Nota : Parameters have been set up in the factory before the delivery of the machine. You must adapt theparameters to the use. They must be modified by an authorized person (refer to list of parameters).

7. FIRST SWITCHING ON

STANDARD MENU

When switching on, the machine is waiting. The 'F1' menu corresponds to the shift to the production mode.There are five different menus : they enable to control the PU 3000.

- F1 : production- F2 : flushing- F3 : parameters- F4 : consumptions- F5 : normal operating of the pumps

To surf from a menu to another, you must move placing the magnet on the sensors indicated with '▲/▼'. The menus scroll as follows :

Countdown on fluid life time.(countdown from 9 to 0; 9 represents 90% ofthe remaining time before the regeneration).

A line is visible when the PU 3000 is flushed.


Arborescence of the menus :

Production Flushing Parameters Consumptions Pumps

8. FIRST PLACING INTO OPERATION

BEFORE SWITCHING ON

Before switching on, half fill the cups with T lubricant or with the appropriate solvent (only for standard fluidsections, not for Flowmax® fluid sections).

Nota : the cup nut must be slightly tightened with the wrench provided. Too much tightening may damagethe cup seals.

Tightening of the wetting cup :

- Fill the cup with T lubricant,

- Start the pump, then tighten the cup after 10 minutes, then 1 hour, then 1 day of operating,

- If you notice any leakage, the cup must be tightened.

Nota : Stop the machine and depressurize the air and fluid networks to tighten the cup.

▲▼ ▲▼

▲▼

▲▼

▲▼

▲▼

ESC

▲▼

▲▼

▲▼

ESC

ESC

ESC

ESC

▲▼

▲▼

▲▼


FLUSHING OF THE PUMPS AND OF THE MACHINE IN SOLVENT

During that first placing into operation, it is compulsory to have all the pumpsinto solvent as well as the machine to ensure the good quality of the fluid get bythe PU 3000.

The fluid pressure must not exceed 1 bar / 14.5 psi on the gauges.

Carry out the connections indicated at § 7 (INSTALLATION),

Immerse the suction rod of the BASE pump in the solvent container,

Close the gun air supply valve,

On the page of the display main menu, enter 'NORMAL OPERATING' (F5 then OK), then selectthe A pump ( or, and OK),

Trigger the gun to start the A pump with solvent and increase the fluid pressure to at least 1 bar /14.5 psi (reading on the gauge) or go through the drain valves,

Release the gun trigger when there are no more air bubbles in the solvent at the gun nozzle,

Immerse the suction rod of the CATALYST pump in a solvent container,

On the page of the display main menu, enter 'NORMAL OPERATING' (F5 then OK), then selectthe B pump ( or, and OK),

Trigger the gun to start the B pump with solvent and increase the fluid pressure to at least 1 bar /14.5 psi (reading on the gauge) or go through the drain valve,


Turn the air valve that supplies air to the flushing pump,

On the page of the display main menu, enter 'FLUSHING MODE' (F2 then OK),

Trigger the gun to prime the SA pump with solvent and increase the fluid pressure to at least 1 bar/ 14.5 psi (reading on the gauge),


Do not modify the factory parameters for the moment.

L K

Caution : Do not supply gun with atomising air to prevent anyatomisation and point the solvent fan into a container.

We advise you to wear protective glasses and gloves.

Go out from the 'NORMAL OPERATING' mode passing to ESC.

Close the air supply valve of the flushing pump.

START UP OF THE MACHINE

Take off the BASE and CATALYST suction rods from the solvent containers and introduce themin their respective container.

Caution : never invert the suction rods.

Open the drain valves located at the outlet of the fluid sections. Start up the pumps. Prime thepumps, then close the drain valves.

Pass to production mode and let the fluid flow until it flows clean. In case of alarm, disable then goto production mode.CAUTION : do not supply atomising air to the gun.

Carry out a flushing to clean the mixed circuit. As soon as the solvent is clean, pass to ESC.

The parameters are preset up in the factory. You can change them (refer to § 11).


MIXING RATIO CHECKING

Remove the 'mixed fluid' hose located on the outlet of themixing unit. Install, instead of it, the fitting (25) and theneedle-valve assembly (19) supplied with the machine.

Take off the control air hose on the VP2A BASE valve.

Connect that hose to the VP3 valve. The VP3 valve isoriginally supplied with a needle valve assembly (19).

Pass in F 5 mode to adjust the opening of the needle-valves.

Prime the A pump and adjust theopening of the needle-valve.

Prime the B pump and adjust theopening of the needle-valve.

Place the beakers underneath the valves. Start up the PU3000 pump, then open the valves.

Input

The PU 3000 passes in test mode and displays

Caution : the fluid pressure must be lower than200 bar / 2900.6 psi.

The BASE and CATA materials are dispensed into thebeakers. After a while, close the needles' valves and checkthe ratio.

Activate ESC to stop the test and only after that you canremoving the test outlet.

Nota : During that stage, you can not use the spray gun.

Nota : design of a pump,model PU 3000 Airmix

When the mixing ratio checking is over, switch off the PU 3000 machine.

Disconnect the air hose from the VP3 valve and connect it to the BASE valve.

Remove the needle-valve assembly (19) and the fitting (25). Screw again the fluid hose on the fitting(M 3/4 JIC) at the outlet of the mixer unit.Start up the machine.

Wear protective glasses to protect the eyes from possible discharges during the handlingof the valves.

Flush the needle valve assembly that has been removed and do not leave the catalystcrystallize : - Flush the CATA test outlet : input F2 to carry out the flushing. When it isclean, activate ESC.

- Flush the BASE test outlet : invert the test outlets and carry out a flushinguntil it is clean.

9. APPLICATION PROGRAMMING (F3)

To alter the parameters of the PU 3000, go to F3, then validate. To shift from a parameter to another, use

the arrows or.

Select the parameter to alter. Depress the key OK , then the arrows orto increase or decrease thevalue. Activate OK to validate the new value or ESC to cancel.

To quit a parameter, activate ESC.

To quit the PARAMETERS menu, activate ESC.

The parameters are pre-set up in the factory. They must be adjusted (by an authorized person) to suit thematerial to be processed.

VP1

VP2A

VP2B

VP3

19

19

25


The calibration of the stroke length is carried out in the factory. When removing the movementsensors or when disassembling the fluid section from the motor, it is important to initialize the pumps(refer to P10).

PASSWORD

When you start the machine for the first time the access code of the menu `Parameters' isdeactivated, everyone is able to modify the machine’s parameters.

To activate this access code you have to :

- enter in the parameter 0 of the menu F3 : « key » « key ».The code ‘’ appears, it’s the code present by default in the machine.

- change the code by using the arrows or and the «key » for each digit which compose thiscode.

Once the access code was validated, the access is protected by the password. Only the people who

know this password and those which know the administrator code ‘’ will be able to reach themenu `Parameters'.

Each time a user wants to enter in the menu 'Parameters' the password will be required: .

The user shall enter the password by using the arrows or and the «key » for each digitwhich compose this code :

- If the entered code is correct, the following fonts appear.

- If the entered code is incorrect, the word ‘appears and the machine allows you to enter thepassword again (Press 'Esc' to return to the principal menu).

If you want to desactivate the password, you just have to parameterise the code ‘’ again asaccess code.


PARAMETERS

Parameters Description Factory adjustment Youradjustments

Parameter of the password

Mixing ratio parameter. Percentage of catalystin the base, from 0,1% to 160%

50 %

Parameters of the mixed fluid life time

Minimum value : 1min

Maximum value : 999 min

30 min

Regeneration volume parameter in cubiccentimetre

Minimum value : 1 c.c

Maximum value : 9 999 cc

200 cc

Section of the A piston

Minimum value: 1 mm2

Maximum value : 99 999 mm2

For fluid section - 50cc :465 (airmix® version),

485 (pneumatic version)

For fluid section -124cc :555 (airless version)

Section of the B piston



For fluid section - 50F :470 (airmix® version),

490 (pneumatic version)

For fluid section - 124cc :555 (airless version)

Injection volume

Minimum value : 0,1 cc

Maximum value : 999,9 cc

4,8 cc

Mixing tolerance

Minimum value : 0,1 %

Maximum value : 100 %

3 %

Alarm volume for the A pump

Minimum value : 1 L

Maximum value : 40 000 L

0 : parameter not taken into account

OK : reset of low level pump shut off –A-

0

Alarm volume for the B pump

Minimum value : 1 L

Maximum value : 40 000 L

0 : parameter not taken into account

OK : reset of low level pump shut off –B-

0

Initialization mode (values of the high and lowthresholds of the movement sensors)

OK : to activate that mode

Flushing time

Minimum value : 10 seconds

Maximum value : 500 seconds

120 s

Flushing volume

Minimum value : 10 cc

Maximum value : 5000 cc

500 cc


Number of thousands of cycles beforepreventive maintenance on the A pump

Minimum value : 1

Maximum value : 9999

500 cyc(i.e. 500 000 cycles)

Number of thousands of cycles beforepreventive maintenance on the B pump

Minimum value : 1

Maximum value : 9999

500 cyc(i.e. 500 000 cycles)

Percentage of dry extract in the base

Minimum value : 0 %

Maximum value : 100 %50 %

Ratio Test mode

OK : to activate that mode

VALIDATION OF THE INITIALIZATION MODE

That mode enables the machine to define the high and low settings of the movement sensor on eachpump.

After validating the parameter, the machine displays A1, and controls the down strokeon the BASE pump piston : open the gun or the BASE drain valve to make the piston go down.

Once the BASE pump piston is in low position, close immediately the valve or the gun avoid the

decompression of the circuit, then input OK.Then, the piston displays A2, it goes up and is waiting for the high setting of the BASE pump. Open thegun or the BASE drain valve to make the piston go up.

Input OK.

The machine displays b1, and controls the down stroke of the CATA pump piston : open the gun or theCATA drain valve to make the piston go down.

Once the CATA pump piston is in low point, close immediately the valve or the gun avoid the

decompression of the circuit, then input OK.

Then, the piston displays b2, it goes up and is waiting for the high setting of the CATA pump : open thegun or the CATA drain valve to make the piston go up. When the piston is up, close immediately thecircuit to avoid the decompression.

Input OK.After that last validation, the machine comes back to the parameter menu.

Caution : that parameter must be modified only when changing the sensor(disassembly or re-cabling) or when updating the software or or of theelectronic card or when changing the a barrier Zener (CA and CB only). If theprocedure is launched, it must be carried out in entirety, if not : the machniewill not work correctly any more.


PRODUCTION (F1)

If the machine is in mixed material, open the gun spraying air supply valve.

Trigger the gun.

Adjust the spraying air regulator to get the desired fan.

When passing to production for the first time, the machine carries out aregeneration.

The display consists of a countdown that enables to know, in percentage (9 between 90% and 100% ofthe volume), the volume remaining to be dispensed according to the P3 parameter. At the end of thatstage, the machine enters in production. You can also activate ESC during the fluid priming; we advice younot to start painting inmediately.

In production, there are 3 main screen messages:

- The operator is spraying and the PU 3000 is operating correctly. The real mixing ratio is displayedon the screen.

- The machine stops because of a malfunction. The kind of breakdown is displayed on the screen,the machine emits an alarm signal to inform the operator (cf § 'TROUBLESHOOTINGS').

- The machine has reached the maximum life duration of the material and passes automatically inregeneration mode. The machine emits an alarm signal to inform the operator. The followingscreen is displayed :

Open the gun until the regeneration ends (shut off spraying air), then the machine passes to production.

To exit from production : activate ESC.

The CATALYST pressure must always be higher by 5 to 10% than theBASE pressure.

If the machine is not in mixed material, a regeneration is automatically carried outto bring the mixed material to the gun.

We advise you to shut off air during that stage.

You can stop the regeneration by activating ESC. Then, the regeneration will stop,but be careful, the quality of the mixed material can be inferior.

Real mixing ratio


FLUSHING (F2)

This menu is used for flushing. When you want to flush the machine, activate OK when you are onthe F2 menu.

After confirming via OK , the machine opens the solvent valve. The buzzer sounds intermittently.Check the solvent pump supply valve is open.

A countdown begins : F2-9, then F2-8.

The machine stops when the countdown is over.

The machine closes the solvent valve and the mixed material flushing has ended.

Nota : Close the spraying air valve during the 'FLUSHING' stage.

During the first flushing, you can determine the solvent volume (F3 P12 parameter) consumedduring the flushing time (F3 P11 parameter). Once determined, enter your parametersaccordingly..

CONSUMPTIONS / PRINT (F4)

The 'F-4' menu enables to view the consumptions of each material (color, catalyst in cc). You can alsoprint the ratio of the consumptions as well as the parameters of the applications : you must connect aconnection cable to the printer (RS 232 connection) (printer not provided).

Consumption of the base Consumption of the VOC

Consumption of the catalyst Enables the user to reset the

consumptions activating the key OKthanks to a sub menu

Consumption of solvent Enables the user to print theconsumptions and the parameters

activating the key OK


Enables the user to reset the consumption of the A pump and the consumption of

VOC activating the key OK

Enables the user to reset the consumption of the B pump activating the key OK

Enables the user to reset the consumption of solvent activating the key OK

Preventative maintenance display : if the number ofpreset cycles on P14, 15 is reached, it enables the userto reset the counters of cycle of the A and B pumps forthe preventive maintenance.Only when the counter has been reached its valueactivating the key , it reinitializes the counter.

Enables the user to reset all the consumptions activating the key OK

▲▼

▲▼

▲▼

▲▼

ESC

OK

Arborescence of the F4.CLr menu :


10. INDICATIONS OF OPERATION GIVEN BY THE MACHINE

INDICATIONS GIVEN BY THE LEDS

Description Function Action

Red LED Fault The machine stops

Orange LED Working Function other than production (flushing, pot-life alarm …)

Green LED Production

Green + orange LED Waiting

LED switched off Programming

MESSAGES GIVEN BY THE DISPLAY UNIT

The messages given by the display unit are for your information only but do not stop the machine.

Number of cycles' overrun indication

Messages Indications

Cyc.A Overrun of the number of cycles configured at the P3 parameter

Cyc.b Overrun of the number of cycles configured at the P14 parameter

Cyc.Ab Overrun of the number of cycles configured at the P13 & P14 parameters

Fluids' consumption alarm

Messages Indications

--A-- A fluid consumption alarm A container empty(volume fixed by the P8 parameter)

OK (during at least 3 seconds) : reset of low level pump shut off –A-

--b-- B fluid consumption alarm B container empty(volume fixed by the P9 parameter)

OK (during at least 3 seconds) : reset of low level pump shut off –B-


11. MAINTENANCE

L K

Never leave mixed material in the machine. Properly adjust the potlife parameterto avoid curing. Carry out a flushing when the work is over.

Flush when ending the work.

SYNOPTIC

A

B

AC

230/115 V

AC

EV

D1

D1 D2

ASA

B

info moteur B

info moteur A

câble

(long. 8m)

MEL

5050F

10/14

VP1

VP2A VP2B

AB

SA

A BSA

D2

/ /S

VR1

Nota : diagram of a pump, model PU 3000 Airmix


MAINTENANCE PLAN

The life duration of the different elements depends on the properties of the material used. Thefollowing maintenance plan is for information only and can not be taken into account whenmaking a complaint.

SUBSET ELEMENT OPERATION TO CARRYOUT

TIMEEXPECTED

PERIODICITY MACHINESTATE

TOOLS

Mixer Mixer Remove and install a newmixer

2 mn 1 year stop

Check the lubricant into thecup : its level (1/2 cup) andits colour (colourless)

2 mn week stop T lubricant

If the lubricant iscontaminated, tighten thewetting cup on the upperpacking (or change theseals of the packing, ifnecessary).

10 mn month stop Wrenchsupplied

BASE pump BASE fluidsection

Remove and clean theparts; change the seals andreinstall.

3 h 1 year stop


2 mn week stop P lubricant



CATA fluidsection, modelstandard

Remove and clean theparts; change the seals andreinstall.

3 h 1 year stop

CATALYSTpump

CATA fluidsection, modelFlowmax

Remove and clean theparts; change the seals andreinstall

4 h 1 year stop


2 mn week stop T lubricant



Flushingpump

Fluid section

Remove and clean theparts; change the seals andreinstall

2 h 1 year stop

Remove and change thecartridge

10 mn 1 year stopPilotedvalve

Piloted valve

Change the piston packing 10 mn 1 year stop

Remove and change thecartridge

10 mn 1 year stopColorchanger

Piloted valve

Change the piston packing 10 mn 1 year stop


TROUBLESHOOTING

For any intervention on the machine :

- Flush the circuits,

- Shut off the compressed air,

- Depressurize the hoses by triggering the gun,

- Shut off the electric supply.

If a problem occurs during the machine operation, alarms will be displayed on the screen of the machine.

Input OK to disable each alarm.

DIAGNOSTICS

ELECTRIC

FAULTS CHECKINGS

Check that the isolating switch is on 'I'.

Check that the mains supply is connected.

No : connect it.

Check that the fuse on the electric card inside thebox is in working order.

No : change the fuse (ind. 3).

The machine does not switch on

Check the electric wiring of the supply cable (badcontact or other)

TROUBLES CAUSES SOLUTIONS

Trouble on the BASE fluid section Check the BASE circuit :

- material in the drum,

- suction rod strainer,

- pump valves.

Clean or change.

Check the CATALYST pressure towardsthe BASE pressure.

Trouble on the CATALYST fluidsection

Check the CATALYST circuit :

- material in the drum,

- suction rod strainer,

- pump valves.

Clean or change.


Incorrect mixing ratio

Flow incorrectly adjusted

Check the material levels in the supplydrums.

Check the starting of the pumps.


Irrelevant data capture between theratio and the injection volume(Machine unable to give theparameters requested)

Check that the P1 parameter (ratio) andthe P6 parameter (injection volume) arecompatible in injection capability termsin relation to the ratio requested.


MATERIAL

FAULTS CHECKINGS

No fluid flows when passing into production orflushing mode.

Check if the valves are open :

No : - Check air supply (minimum 4 bar / 58 psi),

- Check the connection of the 25 pts cable,

- Check the correct operating of theelectrovalves.

Yes : - Check the fluid pressure,

- Check the static mixer.

The machine displays the correct mixing but theconsumption of catalyst is too important.

Check the grounds of the machine (230V intake andground cable of the fluid module)

The machine displays the correct mixing but theconsumption of catalyst is not enough.

Check the grounds of the machine.

When the main menu page is displayed, fluid flowsout when the gun is open.

Check the valvesChecking of the valve : look at what is flowing

-if it is solvent, change the valve (VP1)

-if it is base, change the valve (VP2A)

-if it is catalyst, change the valve (VP2B)

12. PROPORTION AND OUTPUT ACCORDING TO THE RATIO

Ratio (%) Catalyst proportion (cc) Maximum output (cc/mn)

5 2,40 500

10 2,40 1000

15 2,40 1000

20 2,40 1500

30 4,80 2000

50 4,80 2000

60 6,10 2000

100 10 2000


13. MIXING RATIO

A : Base B : Catalyst B / A x 100 = X%

Ex : A = 2.5 B = 1 1 / 2.5 x 100 = 40%

A B % A B %

0.625 1 160 10.5 1 9.524

1 1 100 11 1 9.091

1.5 1 66.7 11.5 1 8.696

2 1 50 12 1 8.333

2.5 1 40 12.5 1 8

3 1 33.3 13 1 7.692

3.5 1 28.6 13.5 1 7.407

4 1 25 14 1 7.143

4.5 1 22.2 14.5 1 6.897

5 1 20 15 1 6.667

5.5 1 18.2 15.5 1 6.452

6 1 16.7 16 1 6.25

6.5 1 15.4 16.5 1 6.061

7 1 14.3 17 1 5.882

7.5 1 13.3 17.5 1 5.714

8 1 12.5 18 1 5.556

8.5 1 11.8 18.5 1 5.405

9 1 11.1 19 1 5.263

9.5 1 10.5 19.5 1 5.128

10 1 10 20 1 5

14. PNEUMATIC AND ELECTRIC DIAGRAMS

Refer to appendices (Doc. # 055.680.031)


SPECIFICATIONS

PU 3000 PUMP- model Pneumatic & model Airmix


15. FEATURES - PU 3000 PNEUMATIC

COMPOSITION

BASE pump Motor : 1500 (only for PU 3000)

Fluid section : 50 cc (standard)

CATALYST pump Motor : 1500 (only for PU 3000)

Fluid section : 50F (Flowmax)

Flushing pump Option : Pump depending upon pressure range

TECHNICAL FEATURES

Maximum air supply pressure 6 bar / 87 psi

Maximum fluid outlet pressure of the PU 3000 0-6 bar / 0-87 psi or 6-40 bar / 87-580 psi

Proportioning ratio / Fluid flow rate Refer to charts (§ 14 & 15)

Electrical supply of the supply unit 115V / 230V - 10W

Air inlet connection F 3/4 BSP (air inlet valve)

Fluid outlet connection (mixer) F 3/4 JIC

The control box of the PU 3000 mixing machine must be installed outsidethe spray booth.

SPECIFIC PARAMETERS

Parameters Description Factory adjustment Your adjustments




485(for fluid section, model 50cc)




490(for fluid section, model 50F)


16. FEATURES - PU 3000 AIRMIX

COMPOSITION

BASE pump Motor : 3000 PU


CATALYST pump Motor : 3000 PU

Fluid section : 50F (Flowmax)


TECHNICAL FEATURES


Maximum fluid outlet pressure of the PU 3000 180 bar / 2610.5 psi






SPECIFIC PARAMETERS









470(for fluid section, model 50F)


17. DISASSEMBLY & REASSEMBLY - PU 3000 PNEUMATIC, PU 3000 AIRMIX

CAUTION : Before any work is carried on the pump, stop the machine aftercarrying out flushing, shut off the compressed air supply and depressurize thecircuits triggering the gun.

The pump is manufactured under the ATEX agreement and can not be modified.KREMLIN REXSON will not be held responsible for any failure to comply with that

instruction.

MIXER

Unscrew the mixer assembly and replace it with a new one.

PILOTED VALVES

12

3

4

5

6

89

10 1111

13141516 7

CARTRIDGE OF A FLUID VALVE (Ind. 9)

Loosen the 3 screws (7) and take off the valve from the module body.

Unscrew the needle (1). Unscrew the cylinder (4).

Hold the rod strainer (6), unscrew the needle rod and remove the cartridge assembly with rod (9).

Assemble the new cartridge (9) into the cylinder support (2) pushing it until the shoulder of the cartridgerests on the shoulder of that support, then reassemble all parts of the valve in the reverse order of thedisassembly.

Present the valve in front of the module body.

Center the cartridge (9) on the module body then reassemble the screws (7).

PISTON PACKING (Ind. 14)

Unscrew the cylinder (4).

Remove the spring (5).

Unscrew the opening signal light (8).

Unscrew the nut (16).

Remove the support washer (15) and the packing(14).

Clean the parts and change them if necessary.

Before reassembling :

Before assembling on the piston (13), take careof shaping the cartridge lip (14) by hand asshown in the above drawing (cartridge turned upon the piston).

The nut (16) must be glued on the piston (13) withloctite adhesive (eg : Loctite 222).

131415164

8

5


FLUID SECTION, MODEL 50 (BASE) (REFER TO DOC. 573.080.050)

Guards (air motor cover, coupling shields, connectors,…) have been designed forsafe use of the equipment.

The manufacturer will not be held responsible for bodily injury or failure and / ordamage to property due to removal or partial removal of the guards.

SUCTION VALVE

Unscrew the suction valve (5) holding the cylinder (2).

The ball (10) is secured on the valve (5) by means of a circular rush (9).

Clean the parts.

Reinstall the suction valve (5) and the seal (25) changing the parts if necessary.

EXHAUST VALVE AND MOBILE PACKING

Unscrew the cylinder (2) and pull it downwards.

Unscrew the exhaust valve (6) holding the piston (3).

Take off the ball (17), the washer (12) and the seal (13).

Clean the parts.

Carry out the reassembly in the reverse order of the disassembly :

- Install the GT seal (13), the GT washer (12) and the ball (17) on the exhaust valve (6).

- Screw the exhaust valve (6) into the piston. Tighten up the seal on the exhaust valve (6).

Change the seal (8) if necessary when assembling the cylinder (2).

UPPER PACKING

Disassemble the piston rod from the motor andthe piston (3) from the fluid section.

Unscrew the wetting-cup (4) by means of thewrench supplied with the pump.

Pull the piston (3) upwards to remove the seals(21 and 22) from the upper packing (18).

Reinstall the seals (21 and 22) taking care of thedirection, the order and the dimension ofassembly.

Tighten the wetting cup (4).

After reassembling the parts, fill the pumpwith solvent and increase the pressure to itsmaximum. Stop the pump and depressurizeopening the drain valve.

Tighten the wetting cup (4) by means of thewrench to be in accordance with the abovedrawing.

Before reassembling the different components :

- Clean the parts with the appropriate cleaning solvent,

- Install new seals if necessary after having lubricated them with PTFE grease,

- Install new parts if necessary..


ASSEMBLY INSTRUCTIONS (FLUID SECTION, MODEL 50)

4

20

22

19

18 21

17

12

13

6

8

2

25

9

10

26

5

24 23

1

3

A 2

A 1

A 1

A 2

A 2

A 1

A 1

A 2

A 1

C 1

A 1

A 1

Index Instruction Description Part number

A 1 PTFE grease PTFE grease (10 ml) 560.440.101

A 2 Anti-seize grease Grease box (450 g / 99 lb) 560.420.005

C 1 Medium strength

Aneorobic Pipe sealant

Loctite 577-


FLUID SECTION, MODEL 50 F (CATALYST) (REFER TO DOC. 573.114.050)



1 - DISASSEMBLY / ASSEMBLY OF THE FLUID SECTION PART

Unscrew the fitting nut (38) and the screws (41 and 43) to remove the connection tube (39).

SUCTION VALVE

Unscrew the suction valve (35) holding the cylinder (27).

The ball (22) is secured on the valve (35) by means of a circular rush (21).

Clean the parts.

Reinstall the suction valve (35) and the seal (23) changing parts if necessary.

EXHAUST VALVE AND MOBILE PACKING

Unscrew the cylinder (27) and pull it downwards.

Unscrew the wetting cup (33) to take off the GT seal (31) from the exhaust valve (34).

Unscrew the exhaust valve (34) holding the piston (24).

Remove the ball (32).

Clean the parts and reinstall then changing the seals if necessary.

UPPER TIGHTNESS SEAL

Unscrew the 4 screws (30).

Remove the tightness seal (28) pulling the exhaust valve (25) downwards.

Change the tightness seal (28), the O-Rings (29 and 11).

Reinstall the parts in the reverse order of the disassembly sequence.

2 - DISASSEMBLY - ASSEMBLY OF THE COUPLING (WITH BELLOWS)

That operation must be carried out after the disassembly of the fluid section part.

BELLOWS

Unscrew the nuts (14) from the coupling tie-rods.

Take off the suction flange (1) and the cylinder (2) pulling them downwards.

Remove screws (12) to separate the suction bearing (3) from the motor.

Separate the intermediate piston (9) from the motor rod.

Put aside the coupling with bellows assembly.

Disassemble the bellows' flange (4) removing the screws (13) to take off the upper part from thebellows.

Unscrew the skirt (8) to take off the lower part from the bellows.

Change the bellows (5).

Install the new bellows pushing it into skirt (8) firmly.

Insert the intermediate piston (9) inside the bellows (5) and screw the skirt at its end.

Insert the bellows and the piston (9) into the bearing (3).

Install the flange (4) into bellows (3) and tighten the whole with the screws (13).

Connect bellows-piston assembly with the motor rod and secure it to the lower support of the motorwith the screws (12).

Reinstall the fluid section piston (24) on the intermediate piston (9).

Change the seals (11) then reinstall the cylinder (2) and the suction flange (1).

Install the whole on the tie-rods and tighten the nuts (14).


Before reassembling the different components :


- Install new seals if necessary, after having lubricated them with PTFE grease.

- Lubricate the piston and the inside of the cylinder to prevent from damaging the seals,

- Install new parts if necessary.

ASSEMBLY INSTRUCTIONS

39

21

38

37

36

35

34

33

32

31

30

29

27

22

24

23

25

28

26

41

40

11

11

43

42

5

8

2

9

10

11

12

13

4

3

1

15

14

20 1

A 1

A 1

C 1

C 1

A 1

A 1

A 1

C 1

A 1

A 2

A 2

A 2

A 1

A 1

C 1




C 1 Medium strength


Loctite 577-


SPECIFICATIONS

PU 3000 PUMP - model Airless


18. FEATURES - PU 3000 AIRLESS

COMPOSITION

Motor : 5000 PUBASE pump


Motor : 5000 PUCATALYST pump



TECHNICAL FEATURES


Maximum fluid outlet pressure of the PU 3000 360 bar / 5222 psi






SPECIFIC PARAMETERS



Minimum value : 1 mm2




Minimum value : 1 mm2




19. DISASSEMBLY & REASSEMBLY - PU 3000 AIRLESS

CAUTION : Before any work is carried on the pump, stop the machine aftercarrying out flushing, shut off the compressed air supply and depressurize thecircuits triggering the gun.

The pump is manufactured under the ATEX agreement and can not be modified.KREMLIN REXSON will not be held responsible for any failure to comply with that

instruction.

MIXER

Unscrew the mixer assembly and replace it with a new one.

ASI 40 VALVES (REFER TO DOC. 573.062.050)

FLUID PACKING (22) AND NEEDLE WITH BALL (37)

Unscrew the diaphragm (9), the seat-holder assembly (17).

Take off the 2 screws (13).

Disassemble the needle holder (23) from the needle strainer (6) to remove the front body (1) from thegun.

Take off the circlip (26) holding the fluid packing (22).

Remove the fluid packing (22) pulling the needle frontwards.

Unscrew the ball needle (37) from the needle holder (23).

Change the fluid packing and its seal (24).

Clean the front part of the gun.

When assembling, drive fluid packing (22) by pushing it from the front part to the rear part of the body(1) until the packing shoulder comes to lean against the shoulder located inside the gun.

Then, secure the fluid packing by means of the circlip (26).

Reinstall the ball needle (37), the screws (13), the seat-holder assembly (17), the diaphram (9), the tipand the coupling nut (8).

PISTON ASSEMBLY (27)

Unscrew the 4 screws (11).

Remove the spring guide (3) and the cylinder (2).

Take off the spring (7), the spring support (33).

Unscrew the nut (31).

Remove the washer (30) and the piston packing (29).

Clean the parts and change them if necessary.

Nota : Before inserting the piston assembly (27) into thecylinder, the packing lip (29) must be shaped by hand asshown opposite (cartridge turned up on the piston).

28 29 30 31 32

AIR PACKING (34)

Take off the back part of the gun and remove the piston as explained before.

Remove the air packing (34).

Replace the packing seal (36) or the air packing assembly.

Nota : when changing the ASI 40 valve from the PU 3000 fluid equipment, take off the fittings from thespare valve delivered, then install it on the fluid equipment.


FLUID SECTION, MODEL ALTO 50CC (BASE) (REFER TO DOC. 573.395.050)

WARNING!

Before any action on the pump, shut off the compressed air supplyand depressurize the systems by triggering the spray gun.



Disassembly of the pump

- Unscrew the 2 nuts (22) and put aside the flange (20), the tie-rods (21) and the protective spring(23),

- Clamp the pump horizontally through the body (2) into a vice,

- Unscrew the foot valve body assembly (14),

- Take off the piston (8) downwards,

- Put aside the cylinder (7).

Lower valve

- Push on the ball (16) to remove the spacer (17),

- Take off the seat (15), the seal (19) and the pin (18),

- Put aside the seal (13),

- Clean the parts, check them if they are not worn or damaged.

Reinstall the parts in the reverse order of the disassembly sequence.

Cup seals

- Unscrew the cup nut (1),

- Take off the washers (3 & 5),

- Put aside the seals: PTFEG seals (4a) & UHMW seals (4b),


Reinstall the parts in the reverse order of the disassembly sequence

Piston head

- Unscrew the seat (10),

- Take off the ball (11), the washers (3 & 5) and the seals (12),

- Change the seals : PTFEG seals (12a) & UHMW seals (12b),


Complete assembly of the fluid section

- Lubricate the cup seals and the piston head seals,

- Slide the piston rod assembly (8) inside the body (2), push itupwards,

- Screw the cylinder (7) (to stop) into the body (2),

- Screw the foot valve body assembly (14) to stop, tighten slightly,

- Reinstall the protective spring (23), the connection flange (20) andthe tie-rods (21). Screw the two nuts (22),

- Assemble the pump to the pneumatic motor.

4a

4b

12b

12a

3

5

5

3


Before intervening on the equipment :


- Install new seals if necessary, after having lubricated them with grease.

- Lubricate the piston and the inside of the cylinder to prevent from damaging the seals,

- Install new parts if necessary.

ASSEMBLY INSTRUCTIONS (FLUID SECTION, MODEL 50cc)

13

5

2 + 6

4

3

1

3

12

5

8

13

7

14

19

15

16

17

18

10

11

A 2

A 2

A 2

A 1

A 1A 1

C 1




C 1 Medium strength


Loctite 577-

electronic mixing machine pu 3000 - grapek actionhp fluid regulator, model 3/8 (260 bar / 3771 psi)...

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